Student Workbook: Coupled Tanks Experiment For Labview Users

student workbook
Coupled Tanks Experiment for LabVIEW ™ Users

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COUPLED TANKS Workbook - Student Version 2

CONTENTS
1 Introduction 4
2 Modeling 5
2.1 Background 5
2.2 Pre-Lab Questions 10
3 Tank 1 Level Control 11

3.1 Background 11
3.3 Lab Experiments 15
3.4 Results 18
4 Tank 2 Level Control 19

4.1 Background 19
4.3 Lab Experiments 22
4.4 Results 26
5 System Requirements 27
5.1 Overview of Files 28
5.2 Calibrating the pressure sensor measurements 28
5.3 Setup for Tank 1 Level Control Simulation 28
5.4 Setup for Tank 1 Level Control 29
5.5 Setup for Tank 2 Level Control Simulation 29
5.6 Setup for Tank 2 Level Control 30
6 Lab Report 31
6.1 Template for Tank 1 Level Control Report 31
6.2 Template for Tank 2 Level Control Report 32
6.3 Tips for Report Format 33
COUPLED TANKS Workbook - Student Version v 1.2

1 INTRODUCTION
The Coupled Tanks plant is a "Two-Tank" module consisting of a pump with a water basin and two tanks. The two
tanks are mounted on the front plate such that flow from the first (i.e. upper) tank can flow, through an outlet orifice
located at the bottom of the tank, into the second (i.e. lower) tank. Flow from the second tank flows into the main
water reservoir. The pump thrusts water vertically to two quick-connect orifices "Out1" and "Out2". The two system
variables are directly measured on the Coupled-Tank rig by pressure sensors and available for feedback. They are
namely the water levels in tanks 1 and 2. A more detailed description is provided in [2]. To name a few, industrial
applications of such Coupled-Tank configurations can be found in the processing system of petro-chemical, paper
making, and/or water treatment plants.
During the course of this experiment, you will become familiar with the design and pole placement tuning of Proportional-
plus-Integral-plus-Feedforward-based water level controllers. In the present laboratory, the Coupled-Tank system
is used in two different configurations, namely configuration #1 and configuration #2, as described in [2]. In config-
uration #1, the objective is to control the water level in the top tank, i.e., tank #1, using the outflow from the pump.
In configuration #2, the challenge is to control the water level in the bottom tank, i.e. tanks #2, from the water flow
coming out of the top tank. Configuration #2 is an example of state coupled system.
Topics Covered
• How to mathematically model the Coupled-Tank plant from first principles in order to obtain the two open-loop
transfer functions characterizing the system, in the Laplace domain.
• How to linearize the obtained non-linear equation of motion about the quiescent point of operation.
• How to design, through pole placement, a Proportional-plus-Integral-plus-Feedforward-based controller for the

Coupled-Tank system in order for it to meet the required design specifications for each configuration.
• How to implement each configuration controller(s) and evaluate its/their actual performance.
Prerequisites
In order to successfully carry out this laboratory, the user should be familiar with the following:
1. See the system requirements in Section 5 for the required hardware and software.
2. Transfer function fundamentals, e.g., obtaining a transfer function from a differential equation.
3. Familiar with designing PID controllers.
4. Basics of LabVIEW™ .

2 MODELING
2.1 Background
2.1.1 Configuration #1 System Schematics
A schematic of the Coupled-Tank plant is represented in Figure 2.1, below. The Coupled-Tank system's nomen-
clature is provided in Appendix A. As illustrated in Figure 2.1, the positive direction of vertical level displacement is
upwards, with the origin at the bottom of each tank (i.e. corresponding to an empty tank), as represented in Figure
3.2.
Figure 2.1: Schematic of Coupled Tank in Configuration #1.
2.1.2 Configuration #1 Nonlinear Equation of Motion (EOM)
In order to derive the mathematical model of your Coupled-Tank system in configuration #1, it is reminded that the
pump feeds into Tank 1 and that tank 2 is not considered at all. Therefore, the input to the process is the voltage to
the pump VP and its output is the water level in tank 1, L1 , (i.e. top tank).
The purpose of the present modelling session is to provide you with the system's open-loop transfer function, G1(s),
which in turn will be used to design an appropriate level controller. The obtained Equation of Motion, EOM, should
be a function of the system's input and output, as previously defined.

Therefore, you should express the resulting EOM under the following format:
∂L1
= f (L1 , Vp )
∂t
where f denotes a function.
In deriving the Tank 1 EOM the mass balance principle can be applied to the water level in tank 1, i.e.,
∂L1
At1 = Fi1 − Fo1 (2.1)
∂t
where At1 is the area of Tank 1. Fi1 and Fo1 are the inflow rate and outflow rate, respectively. The volumetric inflow
rate to tank 1 is assumed to be directly proportional to the applied pump voltage, such that:
Fi1 = Kp Vp
Applying Bernoulli's equation for small orifices, the outflow velocity from tank 1, vo1 , can be expressed by the following
relationship:
√
vo1 = 2gL1
2.1.3 Configuration #1 EOM Linearization and Transfer Func-

tion
In order to design and implement a linear level controller for the tank 1 system, the open-loop Laplace transfer
function should be derived. However by definition, such a transfer function can only represent the system's dynamics
from a linear differential equation. Therefore, the nonlinear EOM of tank 1 should be linearized around a quiescent
point of operation. By definition, static equilibrium at a nominal operating point (Vp0 , L10 ) is characterized by the
Tank 1 level being at a constant position L10 due to a constant water flow generated by constant pump voltage Vp0 .
In the case of the water level in tank 1, the operating range corresponds to small departure heights, L11 , and small
departure voltages, Vp1 , from the desired equilibrium point (Vp0 , L10 ). Therefore, L1 and Vp can be expressed as
the sum of two quantities, as shown below:
L1 = L10 + L11 , Vp = Vp0 + Vp1 (2.2)
The obtained linearized EOM should be a function of the system's small deviations about its equilibrium point
(Vp0 , L10 ). Therefore, one should express the resulting linear EOM under the following format:
∂
L11 = f (L11 , Vp1 ) (2.3)
∂t
Example: Linearizing a Two-Variable Function

Here is an example of how to linearize a two-variable nonlinear function called f (z). Variable z is defined
z ⊤ = [z1 z2 ]
and f (z) is to be linearized about the operating point
z0 ⊤ = [a b]

The linearized function is
( ) ( )
∂f (z) ∂f (z)
fz = f (z0 ) + (z1 − a) + (z2 − b)
∂z1 ∂z2
z=z0 z=z0
For a function, f , of two variables, L1 and Vp , a first-order approximation for small variations at a point (L1 , Vp ) =
(L10 , Vp0 ) is given by the following Taylor's series approximation:
( ) ( )
∂2 ∂ ∂
f (L1 , Vp ) ∼
= f (L10 , Vp0 ) + f (L10 , Vp0 ) + (L1 − L10 ) f (L10 , Vp0 ) (Vp − Vp0 ) (2.4)
∂L1 ∂Vp ∂L1 ∂Vp
Transfer Function
From the linear equation of motion, the system's open-loop transfer function in the Laplace domain can be defined
by the following relationship:
L11 (s)
G1 (s) = (2.5)
Vp1 (s)
The desired open-loop transfer function for the Coupled-Tank's tank 1 system is the following:
Kdc1
G1 (s) = (2.6)
τ1 s + 1
where Kdc1 is the open-loop transfer function DC gain, and τ1 is the time constant.
As a remark, it is obvious that linearized models, such as the Coupled-Tank tank 1's voltage-to-level transfer function,
are only approximate models. Therefore, they should be treated as such and used with appropriate caution, that is
to say within the valid operating range and/or conditions. However for the scope of this lab, Equation 2.5 is assumed
valid over the pump voltage and tank 1 water level entire operating range, Vp_peak and L1_max , respectively.
2.1.4 Configuration #2 System Schematics
A schematic of the Coupled-Tank plant is represented in Figure 2.2, below. The Coupled-Tank system's nomen-
clature is provided in Appendix A. As illustrated in Figure 2.2, the positive direction of vertical level displacement is
upwards, with the origin at the bottom of each tank (i.e. corresponding to an empty tank), as represented in Figure
2.2.
2.1.5 Configuration #2, Nonlinear Equation of Motion (EOM)
This section explains the mathematical model of your Coupled-Tank system in configuration #2, as described in
Reference [1]. It is reminded that in configuration #2, the pump feeds into tank 1, which in turn feeds into tank 2.
As far as tank 1 is concerned, the same equations as the ones explained in Section 2.1.2 and Section 2.1.3 will
apply. However, the water level Equation Of Motion (EOM) in tank 2 still needs to be derived. The input to the tank
2 process is the water level, L1 , in tank 1 (generating the outflow feeding tank 2) and its output variable is the water
level, L2 , in tank 2 (i.e. bottom tank). The purpose of the present modelling session is to guide you with the system's
open-loop transfer function, G2 (s), which in turn will be used to design an appropriate level controller. The obtained
EOM should be a function of the system's input and output, as previously defined.
Therefore, you should express the resulting EOM under the following format:
∂L2
= f (L2 , L1 )
∂t

Figure 2.2: Schematic of Coupled Tank in configuration #1.
In deriving the tank #2 EOM the mass balance principle can be applied to the water level in tank 2 as follows
∂L2
At2 = Fi2 − Fo2
∂t
where At2 is the area of tank 2. Fi2 and Fo2 are the inflow rate and outflow rate, respectively.
The volumetric inflow rate to tank 2 is equal to the volumetric outflow rate from tank 1, that is to say:
Fi2 = Fo1
Applying Bernoulli's equation for small orifices, the outflow velocity from tank 2, vo2 , can be expressed by the following
relationship:
√
vo2 = 2gL2
2.1.6 Configuration #2 EOM Linearization and Transfer Func-

tion
In order to design and implement a linear level controller for the tank 2 system, the Laplace open-loop transfer
function should be derived. However by definition, such a transfer function can only represent the system's dynamics
from a linear differential equation. Therefore, the nonlinear EOM of tank 2 should be linearized around a quiescent
point of operation.

In the case of the water level in tank 2, the operating range corresponds to small departure heights, L11 and L21 ,
from the desired equilibrium point (L10 , L20 ). Therefore, L2 and L1 can be expressed as the sum of two quantities,
as shown below:
L2 = L20 + L21 , L1 = L10 + L11 (2.7)
The obtained linearized EOM should be a function of the system's small deviations about its equilibrium point
(L20 , L10 ). Therefore, you should express the resulting linear EOM under the following format:
∂
L21 = f (L11 , L21 ) (2.8)
∂t
For a function, f , of two variables, L1 and L2 , a first-order approximation for small variations at a point (L1 , L2 ) =
(L10 , L20 ) is given by the following Taylor's series approximation:
( ) ( )
∂2 ∂ ∂
f (L1 , L2 ) ∼
= f (L10 , L20 ) + f (L10 , L20 ) + (L1 − L10 ) f (L10 , L20 ) (L2 − L20 ) (2.9)
∂L1 ∂L2 ∂L1 ∂L2
Transfer Function
From the linear equation of motion, the system's open-loop transfer function in the Laplace domain can be defined
by the following relationship:
L21 (s)
G2 (s) = (2.10)
L11 (s)
the desired open-loop transfer function for the Coupled-Tank's tank 2 system, such that:
Kdc2
G2 (s) = (2.11)
τ2 s + 1
where Kdc2 is the open-loop transfer function DC gain, and τ2 is the time constant.
As a remark, it is obvious that linearized models, such as the Coupled-Tank's tank 2 level-to-level transfer function,
are only approximate models. Therefore, they should be treated as such and used with appropriate caution, that is to
say within the valid operating range and/or conditions. However for the scope of this lab, Equation 2.10 is assumed
valid over tank 1 and tank 2 water level entire range of motion, L1_max and L2_max , respectively.

2.2 Pre-Lab Questions
Answer the following questions:
1. Using the notations and conventions described in Figure 2 derive the Equation Of Motion (EOM) characterizing
the dynamics of tank 1. Is the tank 1 system's EOM linear?
Hint: The outflow rate from tank 1, Fo1 , can be expressed by:
Fo1 = Ao1 vo1 (2.12)
2. The nominal pump voltage Vp0 for the pump-tank 1 pair can be determined at the system's static equilibrium.
By definition, static equilibrium at a nominal operating point (Vp0 , L10 ) is characterized by the water in tank
1 being at a constant position level L10 due to the constant inflow rate generated by Vp0 . Express the static
equilibrium voltage Vp0 as a function of the system's desired equilibrium level L10 and the pump flow constant
Kp . Using the system's specifications given in the Coupled Tanks User Manual ([2]) and the desired design
requirements in Section 3.1.1, evaluate Vp0 parametrically.
3. Linearize tank 1 water level's EOM found in Question #1 about the quiescent operating point (Vp0 , L10 ).
4. Determine from the previously obtained linear equation of motion, the system's open-loop transfer function in
the Laplace domain as defined in Equation 2.5 and Equation 2.6. Express the open-loop transfer function DC
gain, Kdc1 , and time constant, τ1 , as functions of L10 and the system parameters. What is the order and type
of the system? Is it stable? Evaluate Kdc1 and τ1 according to system's specifications given in the Coupled
Tanks User Manual ([2]) and the desired design requirements in Section 3.1.1.
5. Using the notations and conventions described in Figure 2.2, derive the Equation Of Motion (EOM) character-
izing the dynamics of tank 2. Is the tank 2 system's EOM linear?
Hint: The outflow rate from tank 2, Fo2 , can be expressed by:
Fo2 = Ao2 vo2 (2.13)
6. The nominal water level L10 for the tank1-tank2 pair can be determined at the system's static equilibrium. By
definition, static equilibrium at a nominal operating point (L10 , L20 ) is characterized by the water in tank 2 being
at a constant position level L20 due to the constant inflow rate generated from the top tank by L10 . Express
the static equilibrium level L10 as a function of the system's desired equilibrium level L20 and the system's
parameters. Using the system's specifications given in the Coupled Tanks User Manual ([2]) and the desired
design requirements in Section 4.1.1, evaluate L10 .
7. Linearize tank 2 water level's EOM found in Question #5 about the quiescent operating point (L10 , L20 ).
8. Determine from the previously obtained linear equation of motion, the system's open-loop transfer function in
the Laplace domain, as defined in Equation 2.10 and Equation 2.11. Express the open-loop transfer function
DC gain, Kdc2 , and time constant, τ2 , as functions of L10 , L20 , and the system parameters. What is the order
and type of the system? Is it stable? Evaluate Kdc2 and τ2 according to system's specifications given in the
Coupled Tanks User Manual ([2]) and the desired design requirements in Section 4.1.1.

3 TANK 1 LEVEL CONTROL
3.1 Background
3.1.1 Specifications
In configuration #1, a control is designed to regulate the water level (or height) of tank #1 using the pump voltage. The
control is based on a Proportional-Integral-Feedforward scheme (PI-FF). Given a ±1 cm square wave level setpoint
(about the operating point), the level in tank 1 should satisfy the following design performance requirements:
1. Operating level in tank 1 at 15 cm: L10 = 15 cm.

2. Percent overshoot less than 10%: P O1 ≤ 11 %.
3. 2% settling time less than 5 seconds: ts_1 ≤ 5.0 s.

4. No steady-state error: ess = 0 cm.
3.1.2 Tank 1 Level Controller Design: Pole Placement
For zero steady-state error, tank 1 water level is controlled by means of a Proportional-plus-Integral (PI) closed-loop
scheme with the addition of a feedforward action, as illustrated in Figure 3.1, below, the voltage feedforward action
is characterized by:
√
Vp_f f = Kf f _1 Lr_1 (3.1)
and
Vp = Vp1 + Vp_f f (3.2)
As it can be seen in Figure 3.1, the feedforward action is necessary since the PI control system is designed to
compensate for small variations (a.k.a. disturbances) from the linearized operating point (Vp0 , L10 ). In other words,
while the feedforward action compensates for the water withdrawal (due to gravity) through tank 1 bottom outlet
orifice, the PI controller compensates for dynamic disturbances.
Figure 3.1: Tank 1 Water Level PI-plus-Feedforward Control Loop.

The open-loop transfer function G1 (s) takes into account the dynamics of the tank 1 water level loop, as characterized
by Equation 2.5. However, due to the presence of the feedforward loop, G1 (s) can also be written as follows:
L1 (s)
G1 (s) = (3.3)
Vp1 (s)
3.1.3 Second-Order Response
The block diagram shown in Figure 3.2 is a general unity feedback system with compensator, i.e., controller C(s)
and a transfer function representing the plant, P (s). The measured output, Y (s), is supposed to track the reference
signal R(s) and the tracking has to match to certain desired specifications.
Figure 3.2: Unity feedback system.
The output of this system can be written as:
Y (s) = C(s) P (s) (R(s) − Y (s))
By solving for Y (s), we can find the closed-loop transfer function:

Y (s) C(s) P (s)
=
R(s) 1 + C(s) P (s)
The input-output relation in the time-domain for a proportional-integral (PI) controller is

Ki (r − y)
u = Kp (r − y) + (3.4)
s
where Kp is the proportional gain and Ki is the integral gain.
In fact, when a first order system is placed in series with PI compensator in the feedback loop as in Figure 3.2, the
resulting closed-loop transfer function can be expressed as:
Y (s) ωn2
= 2 (3.5)
R(s) s + 2ζ ωn s + ωn2
where ωn is the natural frequency and ζ is the damping ratio. This is called the standard second-order transfer
function. Its response properties depend on the values of ωn and ζ.
Peak Time and Overshoot
Consider a second-order system as shown in Equation 3.5 subjected to a step input given by
R0
R(s) = (3.6)
s
with a step amplitude of R0 = 1.5. The system response to this input is shown in Figure 3.3, where the red trace is
the response (output), y(t), and the blue trace is the step input r(t).

Figure 3.3: Standard second-order step response.
The maximum value of the response is denoted by the variable ymax and it occurs at a time tmax . For a response
similar to Figure 3.3, the percent overshoot is found using
100 (ymax − R0 )
PO = (3.7)
R0
From the initial step time, t0 , the time it takes for the response to reach its maximum value is
tp = tmax − t0 (3.8)
This is called the peak time of the system.
In a second-order system, the amount of overshoot depends solely on the damping ratio parameter and it can be
calculated using the equation ( )
− √π ζ
1−ζ 2
P O = 100 e (3.9)
The peak time depends on both the damping ratio and natural frequency of the system and it can be derived as
π
tp = √ (3.10)
ωn 1 − ζ 2
Tank 1 level response 2% Settling Time can be expressed as follows:

4
ts = (3.11)
ζω
Generally speaking, the damping ratio affects the shape of the response while the natural frequency affects the
speed of the response.

1. Analyze tank 1 water level closed-loop system at the static equilibrium point (Vp0 , L10 ) and determine and
evaluate the voltage feedforward gain, Kf f _1 , as defined by Equation 3.1.
2. Using tank 1 voltage-to-level transfer function G1 (s) determined in Section 2.2 and the control scheme block
diagram illustrated in Figure 3.1, derive the normalized characteristic equation of the water level closed-loop
system.
Hint#1: The feedforward gain Kf f _1 does not influence the system characteristic equation. Therefore, the
feedforward action can be neglected for the purpose of determining the denominator of the closed-loop transfer
function. Block diagram reduction can be carried out.
Hint#2: The system's normalized characteristic equation should be a function of the PI level controller gains,
Kp_1 , and Ki_1 , and system's parameters, Kdc_1 and τ1 .
3. By identifying the controller gains Kp_1 and Ki_1 , fit the obtained characteristic equation to the second-order
standard form expressed below:
s2 + 2ζ1 ωn1 s + ωn1

2
=0 (3.12)
Determine Kp_1 and Ki1 as functions of the parameters ωn1 , ζ1 , Kdc_1 , and τ1 using Equation 3.5.
4. Determine the numerical values for Kp_1 and Ki_1 in order for the tank 1 system to meet the closed-loop desired
specifications, as previously stated.

3.3 Lab Experiments
3.3.1 Objectives
• Tune through pole placement the PI-plus-feedforward controller for the actual water level in tank 1 of the
Coupled-Tank system.
• Implement the PI-plus-feedforward control loop for the actual Coupled-Tank's tank 1 level.
• Run the obtained PI-plus-feedforward level controller and compare the actual response against the controller
design specifications.
• Run the system's simulation simultaneously, at every sampling period, in order to compare the actual and
simulated level responses.
3.3.2 Tank 1 Level Control Simulation
Experimental Setup
The Coupled Tanks -Tank1 Level Control simulation VI shown in Figure 3.4 is used to perform tank 1 level control
simulation exercises in this laboratory.
Figure 3.4: VI used to run PI-FF control Simulation on Coupled Tanks system in configuration #1.
IMPORTANT: Before you can conduct these simulations, you need to make sure that the lab files are configured
according to your setup. If they have not been configured already, then you need to go to Section 5 to configure the
lab files first.
Follow this procedure:
1. In Coupled Tanks.lvproj, open Coupled Tanks- Tank1 Level Control Simulation.vi. The model implements the
system's simulation Proportional-plus-Integral (PI) closed-loop with feedforward action, as studied in Section
3.1.2. To familiarize yourself with the diagram, it is suggested that you open the model subsystems to get a
better idea of their composing blocks as well as take note of the I/O connections.
2. To generate a square wave that goes between 14 and 16 cm for the tank 1 level reference, go to the Amplitude
Command (cm) section and set the controls to the following:
• Amplitude = 1 cm

• Frequency = 0.02 Hz
• Offset = 15 cm
The total level setpoint for tank 1 should result to be a square wave of ±1cm around the desired equilibrium
level L10
3. Enter the proportional, integral, and feedforward control gains found in Section 3.2 in the kp_1, ki_1, and kff_1
controls in the Control Parameters section on the front panel. Have your lab assistant check your values.
4. Run the VI.
5. The VI should start the Coupled Tanks simulation filling tank 1 up to its operating level L10 . Then after a 15-
second settling delay (in order to stabilize the system at its operating point), the water level in tank 1 should start
tracking the desired ±1cm square wave setpoint around the desired operating level L10 . The corresponding
commanded pump voltage, which is proportional to the control effort spent, can also be monitored and plotted
on-line.
6. Attach plots showing the Implemented Tank 1 Level Control response and the input voltage.
7. Assess the actual performance of the level response and compare it to the design requirements. Measure
your response actual percent overshoot and settling time. Are the design specifications satisfied? Explain. If
your level response does not meet the desired design specifications, review your PI-plus-Feedforward gain
calculations and/or alter the closed-loop pole locations until they do. If you are still unable to achieve the
required performance level, ask your T.A. for advice. Does the response satisfy the specifications given in
Section 3.1.1?
Hint: Use the graph cursors in the Measure tab to take measurements.
3.3.3 Tank 1 Level Control Implementation
Experimental Setup
The Coupled Tanks Tank1 Level Control VI shown in Figure 3.5 is used to perform tank 1 level control exercises in
this laboratory. This VI interfaces with the pump and pressure sensors of the Coupled Tanks system.
Note that a first-order low-pass filter with a cut-off frequency of 2.5 Hz is added to the output signal of the tank 1 level
pressure sensor. This filter is necessary to attenuate the high-frequency noise content of the level measurement.
Such a measurement noise is mostly created by the sensor's environment consisting of turbulent flow and circulating
air bubbles. Although introducing a short delay in the signals, low-pass filtering allows for higher controller gains in
the closed-loop system, and therefore for higher performance. Moreover, as a safety watchdog, the controller will
stop if the water level in either tank 1 or tank 2 goes beyond 27 cm.
IMPORTANT: Before you can conduct these experiments, you need to make sure that the lab files are configured
lab files first.
1. In Coupled Tanks.lvproj, open Coupled Tanks Tank1 Level Control.vi. The model implements the system's
actual Proportional-plus-Integral (PI) closed-loop with feedforward action. To familiarize yourself with the dia-
gram, it is suggested that you open the model subsystems to get a better idea of their composing blocks as
well as take note of the I/O connections.
• Offset = 15 cm

Figure 3.5: VI used to run PI-FF control on Coupled Tanks system in configuration #1.
The total level setpoint for tank 1 should result to be a square wave of ±1 cm around the desired equilibrium
level L10
3. Enter the proportional, integral, and feedforward control gains found in Section 3.2 in the Kp, Ki, and Kff controls
in the Control Parameters section on the front panel. Have your lab assistant check your values.
4. Run the VI. The pump should start running and filling up tank 1 to its operating level, L10 . After a settling delay,
the water level in tank 1 should begin tracking the ±1 cm square wave setpoint (about operating level L10 ).
required performance level, ask your lab instructors for advice. Does the response satisfy the specifications
given in Section 3.1.1?
7. Specifically discuss in your lab report the following points:
• How does your actual tank 1 level compare to the simulated response?
• From the plot of the actual level response, measure your system settling time and percentage overshoot.
Are the values in agreement with the design specifications? If not exactly, find some of the possible
reasons.
• Include in your lab report your final values for Kp_1 , Ki_1 , and Kf f _1 as well as the resulting response plot
of the actual and theoretical L1 versus Lr_1 . Also include from the same run the corresponding plot of Vp .
Ensure to properly document all your results and observations before moving on the the next section.
• You can now proceed to the next section, which deals with the actual implementation of your PI-plus-
Feedforward level controller for tank 2 of the Coupled-Tank system in configuration #2.

3.4 Results
Fill out Table 3.1 with your answers from your control lab results - both simulation and implementation.
Description Symbol Value Units

Pre Lab Questions
Tank 1 Control Gains
√
Feed Forward Control Gain Kf f1 V/ cm
Proportional Control Gain kp1 V/cm
Integral Control Gain ki1 V/(cm-s)
Tank 2 Control Simulation
Steady-state error ess cm
Settling time ts1 s
Percent overshoot P O1 %
Tank 2 Control Implementation
Settling time ts1 s
Table 3.1: Results

4 TANK 2 LEVEL CONTROL
4.1 Background
4.1.1 Specifications
In configuration #2, the pump feeds tank 1 and tank 1 feeds tank 2. The designed closed-loop system is to control
the water level in tank 2 (i.e. the bottom tank) from the water flow coming out of tank 1, located above it. Similarly
to configuration #1, the control scheme is based on a Proportional-plus-Integral-plus-Feedforward law.
In response to a desired ± 1 cm square wave level setpoint from tank 2 equilibrium level position, the water height
behaviour should satisfy the following design performance requirements:
1. Tank 2 operating level at 15 cm: L20 = 15 cm.

2. Percent overshoot should be less than or equal to 10%: P O2 ≤ 10.0 %.
3. 2% settling time less than 20 seconds: ts,2 ≤ 20.0 s.
4. No steady-state error: ess,2 = 0 cm.
4.1.2 Tank 2 Level Controller Design: Pole Placement
For zero steady-state error, tank 1 water level is controlled by means of a Proportional-plus-Integral (PI) closed-loop
scheme with the addition of a feedforward action, as illustrated in Figure 4.1, below.
In the block diagram depicted in Figure 4.1, the water level in tank 1 is controlled by means of the closed-loop system
previously designed in Section 3.1. This is represented by the tank 1 closed-loop transfer function defined below:
L1 (s)
T1 (s) = (4.1)
Lr_1 (s)
Such a subsystem represents an inner (or nested) level loop. In order to achieve a good overall stability with such
a configuration, the inner level loop (i.e. tank 1 closed-loop system) must be much faster than the outer level loop.
This constraint is met by the previously stated controller design specifications, where ts_1 ≤ ts_2 .
However for the sake of simplicity in the present analysis, the water level dynamics in tank 1 are neglected. There-
fore, it is assumed hereafter that:
L1 (t) = Lr_1 (t) i.e. T1 (s) = 1 (4.2)
Furthermore as depicted in Figure 4.1, the level feedforward action is characterized by:
Lf f _1 = Kf f _2 Lr_2 (4.3)
and
L1 = L11 + Lf f _1 (4.4)

The level feedforward action, as seen in Figure 4.1, is necessary since the PI control system is only designed to
compensate for small variations (a.k.a. disturbances) from the linearized operating point L10 , L20 . In other words,
while the feedforward action compensates for the water withdrawal (due to gravity) through tank 2's bottom outlet
orifice, the PI controller compensates for dynamic disturbances.
Figure 4.1: Tank 2 Water Level PI-plus-Feedforward Control Loop.
The open-loop transfer function G2 (s) takes into account the dynamics of the tank 2 water level loop, as characterized
by Equation 2.10. However, due to the presence of the feedforward loop and the simplifying assumption expressed
by Equation 4.2, G2 (s) can also be written as follows:
L2 (s)
G2 (s) = (4.5)
L1 (s)

1. Analyze tank 2 water level closed-loop system at the static equilibrium point (L10 , L20 ) and determine and
evaluate the voltage feedforward gain, Kf f _2 , as defined by Equation 4.3.
2. Using tank 2 voltage-to-level transfer function G2 (s) determined in Section 2 and the control scheme block
diagram illustrated in Figure 4.1, derive the normalized characteristic equation of the water level closed-loop
system.
Hint#1: Block diagram reduction can be carried out.
Hint#2: The system's normalized characteristic equation should be a function of the PI level controller gains,
Kp_2 , and Ki_2 , and system's parameters, Kdc_2 and τ2 .
3. By identifying the controller gains Kp_2 and Ki_2 , fit the obtained characteristic equation to the standard second-
order equation: s2 + 2ζ2 ωn2 s + ωn2
2
= 0. Determine Kp_2 and Ki2 as functions of the parameters ωn2 , ζ2 , Kdc_2 ,
and τ2 .
4. Determine the numerical values for Kp_2 and Ki_2 in order for the tank 2 system to meet the closed-loop desired
specifications, as previously stated.

4.3 Lab Experiments
4.3.1 Objectives
• Tune through pole placement the PI-plus-Feedforward controller for the actual water level of the Coupled-Tank
system's tank 2.
• Implement the PI-plus-Feedforward control loop for the actual tank 2 water level.
• Run the obtained Feedforward-plus-PI level controller and compare the actual response against the controller
design specifications.
• Run the system's simulation simultaneously, at every sampling period, in order to compare the actual and
simulated level responses.
• Investigate the effect of the nested PI-plus-Feedforward level control loop implemented for tank 2.
4.3.2 Tank 2 Level Control Simulation
Experimental Setup
The Coupled Tanks -Tank2 Level Control simulation VI shown in Figure 4.2 is used to perform tank 2 level control
simulation exercises in this laboratory.
Figure 4.2: VI used to run PI-FF control Simulation on Coupled Tanks system in configuration #2.
IMPORTANT: Before you can conduct these simulations, you need to make sure that the lab files are configured
lab files first.
1. In Coupled Tanks.lvproj, open Coupled Tanks- Tank2 Level Control Simulation.vi. The model implements the
system's simulation Proportional-plus-Integral (PI) closed-loop with feedforward action, as studied in Section
4.1.2. As mentioned in the pre-lab assignments, the tank 2 water level control loop is based on tank 1 level
controller, as developed and tuned in the previous sections. The level controller diagram for the Coupled-Tank
in configuration #2 also interfaces directly with your Coupled-Tank hardware. To familiarize yourself with the
diagram, it is suggested that you open the model subsystems to get a better idea of their composing blocks as
well as take note of the I/O connections.

• Offset = 15 cm
level L20
controls in the Control Parameters section on the front panel. Keep in the the PI-plus-feedforward controller
gains for tank 1 of the Coupled-Tank system in configuration #1, as previously implemented. Those are kp_1,
ki_1, and kff_1 controls in the Control Parameters section on the front panel. Have your lab assistant check
your values.
4. Run the VI.

5. The VI should start the Coupled Tanks simulation filling tank1 and tank 2 up to their operating levels L10 and
L20 , respectively. Then after a 35-second settling delay (in order to stabilize the system at its operating point),
the water level in tank 2 should start tracking the desired ±1cm square wave setpoint around the desired
operating level L20 . The corresponding commanded pump voltage, which is proportional to the control effort
spent, can also be monitored and plotted on-line.
required performance level, ask your lab instructor for advice. Does the response satisfy the specifications
4.3.3 Tank 2 Level Control Implementation
Experimental Setup
The Coupled Tanks Tank2 Level Control VI shown in Figure 4.3 is used to perform tank 2 level control exercises
in this laboratory. This VI interfaces with the pump and pressure sensors of the Coupled Tanks system. It should
be noted that two simple low-pass filters cut-off frequency 2.5 Hz are added to the output signal of the tank 1 and
tank 2 level pressure sensors. These filters are necessary to attenuate the high-frequency noise content of the level
measurements. Such a measurement noise is mostly created by the sensors environment made of turbulent flow
and circulating air bubbles. Although introducing a short delay in the signals, low-pass filtering allows for higher
controller gains in the closed-loop system, and therefore for higher performance. Moreover, as a safety watchdog,
the controller will stop if the water level in either tank 1 or tank 2 goes beyond 27cm.
IMPORTANT: Before you can conduct these experiments, you need to make sure that the lab files are configured
lab files first.
1. In Coupled Tanks.lvproj, open Coupled Tanks Tank2 Level Control.vi. The model implements the system's
actual Proportional-plus-Integral (PI) closed-loop with feedforward action, as studied in Assignment #3. To
familiarize yourself with the diagram, it is suggested that you open the model subsystems to get a better idea
of their composing blocks as well as take note of the I/O connections.

Figure 4.3: VI used to run PI-FF control on Coupled Tanks system in configuration #2.
• Offset = 15 cm
level L20
controls in the Control Parameters section on the front panel. Keep in the the PI-plus-feedforward controller
gains for tank 1 of the Coupled-Tank system in configuration #1, as previously implemented. Those are kp_1,
ki_1, and kff_1 controls in the Control Parameters section on the front panel. Have your lab assistant check
your values.
4. Run the VI.

5. The VI should start the gear pump thrusting water filling tank1 and tank 2 up to their operating levels L20 .
Then after a 35-second settling delay (in order to stabilize the system at its operating point), the water level in
tank 2 should start tracking the desired ±1cm square wave setpoint around the desired operating level L20 .
The corresponding commanded pump voltage, which is proportional to the control effort spent, can also be
monitored and plotted on-line.
required performance level, ask your lab instructor for advice. Does the response satisfy the specifications
8. Specifically discuss in your lab report the following points:
• How does your actual tank 2 level compare to the simulated response?

• From the plot of the actual level response, measure your system settling time and percentage overshoot.
Are the values in agreement with the design specifications? If not exactly, find some of the possible
reasons.
• Include in your lab report your final values for Kp_2 , Ki_2 , and Kf f _2 as well as the resulting response plot
of the actual and theoretical L2 versus Lr_2 . Also include from the same run the corresponding plot of Vp .
Ensure to properly document all your results and observations before moving on the the next section.
• You can now proceed to the next section, which deals with the actual implementation of your PI-plus-
Feedforward level controller for tank 2 of the Coupled-Tank system in configuration #2.

4.4 Results
Fill out Table 4.1 with your answers from your control lab results - both simulation and implementation.
Description Symbol Value Units

Pre Lab Questions
Tank 2 Control Gains
Feed Forward Control Gain Kf f2 cm/cm
Proportional Control Gain kp2 cm/cm
Integral Control Gain ki2 1/(s)
Tank 2 Control Simulation
Settling time ts2 s
Tank 2 Control Implementation
Settling time ts2 s
Table 4.1: Results

5 SYSTEM REQUIREMENTS
Required Software
Make sure LabVIEW™ is installed with the following required add-ons:
1. LabVIEW™
2. NI-DAQmx
3. NI LabVIEW™ Control Design and Simulation Module
4. Quanser Rapid Control Prototyping Toolkitr
Note: Make sure the Quanser Rapid Control Prototyping (RCP) Toolkit is installed after LabVIEW. See the RCP
Toolkit Quick Start Guide for more information.
Required Hardware
• Data acquisition (DAQ) device that is compatible with Quanser Rapid Control Prototyping Toolkitr . This in-
cludes Quanser DAQ boards such as Q2-USB, Q8-USB, QPID, and QPIDe and some National Instruments
DAQ devices.
• Quanser Coupled Tanks.

• Quanser VoltPAQ-X1 power amplifier, or equivalent.
Before Starting Lab
Before you begin this laboratory make sure:
• LabVIEW™ is installed on your PC.

• DAQ device has been successfully tested (e.g., using the test software in the Quick Start Guide).
• Coupled Tanks and amplifier are connected to your DAQ board as described Reference [2].

5.1 Overview of Files
File Name Description

Coupled Tanks User Manual.pdf This manual describes the hardware of the Coupled Tanks
system and explains how to setup and wire the system for
the experiments.
Coupled Tanks Workbook (Student).pdf This laboratory guide contains pre-lab questions and lab
experiments demonstrating how to design and implement
controllers for on the Coupled Tanks plant using Lab-
VIEW™ .
Coupled Tanks.lvproj LabVIEW project that contains all the LabVIEW™ Virtual
Instrument (VI) files required for running the Quanser Cou-
pled Tanks labs.
Coupled Tanks -Calibration.vi VI that is used to calibrate the pressure sensor measure-
ments on the Coupled Tanks system.
Coupled Tanks -Tank1 Level Simula- VI that simulates Tank1 level controller (configuration 1)for
tion.vi the Coupled Tanks system.
Coupled Tanks -Tank2 Level Simula- VI that simulates Tank2 level controller (configuration 2)
tion.vi for the Coupled Tanks system.
Coupled Tanks -Tank1 Level Control.vi VI that implements the PI Tank1 level controller (configu-
ration 1) on the Coupled Tanks system using LabVIEW™
.
Coupled Tanks -Tank2 Level Control.vi VI that implements the Tank2 level controller on the Cou-
pled Tanks system using LabVIEW™ .
Table 5.1: Files supplied with the Coupled Tanks
5.2 Calibrating the pressure sensor measurements

Follow these steps:
1. Load the LabVIEW™ software.

2. Open the LabVIEW Project COUPLEDTANK.lvproj.
3. Open the LabVIEW VI called Coupled Tanks- Calibration.

4. Follow the steps in the VI to calibrate both pressure sensors. The sensors should measure about 0V when
empty and about 4.1V when filled up to 25cm.
5.3 Setup for Tank 1 Level Control Simulation

Follow these steps:
1. Load the LabVIEW™ software.
2. Open the LabVIEW Project COUPLEDTANK.lvproj.

3. Open the LabVIEW VI called Coupled Tanks- Tank 1 Control Simulation, shown in Figure 3.4.
4. Ensure the PI-FF control gains the kp_1, ki_1, and kff_1 on the VI front panel are set to the value found in the
Pre-Lab Questions in Section 3.2.

5.4 Setup for Tank 1 Level Control
Follow these steps to get the system ready for this lab:
1. Setup the Coupled Tanks as detailed in the Coupled Tanks User Manual ([2]).
2. If using the VoltPAQ-X1, make sure the Gain switch is set to 3.
3. Open COUPLEDTANK.lvproj project as outlined in Section 5.3.
4. Open Coupled Tanks- Tank1 Level Control.vi shown in Figure 3.5.
5. As discussed in Section 5.3, set the PI gains according to the Pre-Lab Exercise values.
6. Configure DAQ: Ensure the HIL Initialize block is configured for the DAQ device that is installed in your system.
To do this, go to the block diagram (CTRL-E) and double click on the HIL Initialize Express VI shown in Figure
5.1.
Figure 5.1: HIL Initialize Express VI
7. Under the Main tab, select the data acquisition device that is installed on your system in the Board type section.
For example, in Figure 5.2 the Q2-USB is chosen.
Figure 5.2: Select DAQ board that will be used to control system
5.5 Setup for Tank 2 Level Control Simulation

Follow these steps:
1. Load LabVIEW™ and open COUPLEDTANK.lvproj.

2. Open the Coupled Tanks- Tank2 Level Control Simulation VI, shown in Figure 4.2.
3. Make sure the control gains are set to the values found in Section 4.2.
4. Ensure the PI-FF control gains the kp_2, ki_2, and kff_2 on the VI front panel are set to the value found in the
Pre-Lab Questions in Section 4.2.

5.6 Setup for Tank 2 Level Control
Follow these steps to get the system ready for this lab:
1. Go through step 1-4 in Section 5.4 to setup the Coupled Tankssystem and open COUPLEDTANK.lvproj.
2. Open Coupled Tanks-Tank 2 Level Control.vi shown in Figure 4.3.

3. Make sure the control gains are set as dictated in Section 5.5.
4. Configure DAQ: Ensure the HIL Initialize Express VI is configured as explained in Section 5.4.

6 LAB REPORT
This laboratory contains two groups of experiments, namely,
1. Tank 1 Level control, and

2. Tank 2 Level control.
For each experiment, follow the outline corresponding to that experiment to build the content of your report. Also,
in Section 6.3 you can find some basic tips for the format of your report.
6.1 Template for Tank 1 Level Control Report

I. PROCEDURE
1. Simulation
• Briefly describe the main goal of the simulation.

• Briefly describe the simulation procedure in Step 6 in Section 3.3.2.
2. Implementation
• Briefly describe the main goal of this experiment.

• Briefly describe the experimental procedure in Step 5 in Section 3.3.3.
II. RESULTS
Do not interpret or analyze the data in this section. Just provide the results.
1. Response plot from step 6 in Section 3.3.2, Tank1 level control simulation.
2. Response plot from step 5 in Section 3.3.3, Tank 1 level control implementation.
3. Provide applicable data collected in this laboratory (from Table 3.1).
III. ANALYSIS
Provide details of your calculations (methods used) for analysis for each of the following:
1. Peak time, percent overshoot, steady-state error, and input voltage in Step 7 in Section 3.3.2.
IV. CONCLUSIONS
Interpret your results to arrive at logical conclusions for the following:
1. Whether the controller meets the specifications in Step 7 in Section 3.3.2, Tank1 level control simulation.
2. Whether the controller meets the specifications in Step 6 in Section 3.3.3, Tank1 level control implementation.

6.2 Template for Tank 2 Level Control Report
I. PROCEDURE
1. Simulation
• Briefly describe the main goal of the simulation.

• Briefly describe the simulation procedure in Step 6 in Section 4.3.2.
2. Implementation
• Briefly describe the main goal of this experiment.

• Briefly describe the experimental procedure in Step 6 in Section 4.3.3.
II. RESULTS
Do not interpret or analyze the data in this section. Just provide the results.
1. Response plot from step 6 in Section 4.3.2, Tank2 level control simulation.
2. Response plot from step 6 in Section 4.3.3, Tank2 level control implementation.
3. Provide applicable data collected in this laboratory (from Table 4.1).
III. ANALYSIS
Provide details of your calculations (methods used) for analysis for each of the following:
IV. CONCLUSIONS
Interpret your results to arrive at logical conclusions for the following:
1. Whether the controller meets the specifications in Step 7 in Section 4.3.3, Tank2 level control implementation.

6.3 Tips for Report Format
PROFESSIONAL APPEARANCE
• Has cover page with all necessary details (title, course, student name(s), etc.)
• Each of the required sections is completed (Procedure, Results, Analysis and Conclusions).
• Typed.
• All grammar/spelling correct.

• Report layout is neat.
• Does not exceed specified maximum page limit, if any.

• Pages are numbered.
• Equations are consecutively numbered.

• Figures are numbered, axes have labels, each figure has a descriptive caption.
• Tables are numbered, they include labels, each table has a descriptive caption.
• Data are presented in a useful format (graphs, numerical, table, charts, diagrams).
• No hand drawn sketches/diagrams.
• References are cited using correct format.

REFERENCES
[1] Quanser Inc. Coupled Tank User Manual, 2012.

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relating to traditional or modern control applications of process control. For more
information please contact info@quanser.com
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Coupled Tanks Experiment for LabVIEW ™ Users

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COUPLED TANKS Workbook - Student Version 2

3 Tank 1 Level Control 11

4 Tank 2 Level Control 19

COUPLED TANKS Workbook - Student Version v 1.2

• How to design, through pole placement, a Proportional-plus-Integral-plus-Feedforward-based controller for the

COUPLED TANKS Workbook - Student Version 4

2.1.1 Conﬁguration #1 System Schematics

Figure 2.1: Schematic of Coupled Tank in Configuration #1.

2.1.2 Conﬁguration #1 Nonlinear Equation of Motion (EOM)

COUPLED TANKS Workbook - Student Version v 1.2

where f denotes a function.

2.1.3 Conﬁguration #1 EOM Linearization and Transfer Func-

L1 = L10 + L11 , Vp = Vp0 + Vp1 (2.2)

where f denotes a function.

Example: Linearizing a Two-Variable Function

COUPLED TANKS Workbook - Student Version 6

2.1.4 Conﬁguration #2 System Schematics

2.1.5 Conﬁguration #2, Nonlinear Equation of Motion (EOM)

COUPLED TANKS Workbook - Student Version v 1.2

where f denotes a function.

2.1.6 Conﬁguration #2 EOM Linearization and Transfer Func-

COUPLED TANKS Workbook - Student Version 8

L2 = L20 + L21 , L1 = L10 + L11 (2.7)

where f denotes a function.

COUPLED TANKS Workbook - Student Version v 1.2

Fo1 = Ao1 vo1 (2.12)

Fo2 = Ao2 vo2 (2.13)

COUPLED TANKS Workbook - Student Version 10

1. Operating level in tank 1 at 15 cm: L10 = 15 cm.

3. 2% settling time less than 5 seconds: ts_1 ≤ 5.0 s.

3.1.2 Tank 1 Level Controller Design: Pole Placement

Vp = Vp1 + Vp_f f (3.2)

Figure 3.1: Tank 1 Water Level PI-plus-Feedforward Control Loop.

COUPLED TANKS Workbook - Student Version v 1.2

3.1.3 Second-Order Response

Figure 3.2: Unity feedback system.

The output of this system can be written as:

Y (s) = C(s) P (s) (R(s) − Y (s))

By solving for Y (s), we can find the closed-loop transfer function:

The input-output relation in the time-domain for a proportional-integral (PI) controller is

where Kp is the proportional gain and Ki is the integral gain.

Peak Time and Overshoot

COUPLED TANKS Workbook - Student Version 12

This is called the peak time of the system.

Tank 1 level response 2% Settling Time can be expressed as follows:

COUPLED TANKS Workbook - Student Version v 1.2

s2 + 2ζ1 ωn1 s + ωn1

COUPLED TANKS Workbook - Student Version 14

3.3.2 Tank 1 Level Control Simulation

Follow this procedure:

COUPLED TANKS Workbook - Student Version v 1.2

3.3.3 Tank 1 Level Control Implementation

Follow this procedure:

COUPLED TANKS Workbook - Student Version 16

COUPLED TANKS Workbook - Student Version v 1.2

Description Symbol Value Units

Table 3.1: Results

COUPLED TANKS Workbook - Student Version 18